In this paper, 3D Finite Element Method (FEM)-based numerical modelling of precision hard turning has been studied to investigate the effects of chamfered edge geometry on tool forces, temperatures and stresses in machining of AISI 52100 steel using low-grade Polycrystalline Cubic Boron Nitrite (PCBN) inserts. An Arbitrary Lagrangian Eulerian (ALE)-based numerical modelling is employed for 3D precision hard turning. The Johnson-Cook plasticity model is used to describe the work material behaviour. A detailed friction modelling at the tool-chip and tool-work interfaces is also carried. Work material flow around the chamfer geometry of the cutting edge is carefully modelled with adaptive meshing simulation capability. In process simulations, feed rate and cutting speed were kept constant and analysis was focused on forces, temperatures and tool stresses. Results revealed good agreements between FEM results and those reported in literature about experimental ones.
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Arrazola et al. (2008) studied this question.
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